CNC machining services are becoming increasingly popular due to high precision, outstanding productivity, strong capability, and versatility. But when we not maintain it properly or do some wrong operations, its efficiency and product quality will be affected. What are the most common problems in CNC machine? In this article, we’ll discuss the errors in the CNC machining process and how to solve them.
CNC machines are valuable and durable equipment used to complete various machining operations on the workpiece. The most common problems in CNC machine are often used by user error and poor maintenance. It’s necessary to identify the issues and find solutions to solve these problems. Here we present the most common CNC machining problems.
1. Improper Tools or Settings
Improper cutting tool, the tool tip is damaged and not sharp, or improper cutting coolant/lube, these will cause the poor surface finish on the part, and even leave cutter mark on the material, which speeds up the tool wear at the same time. In addition, when the feed rate is too low, the part will remain in the path of cutting tool longer than the required time, resulting in the workpiece being burnt. If the feed rate is too high or the cutter needs to be replaced, it’s easy to leave rough edges and raised marks. Wrong specifications may cause burns to tools.
– Replace the tool with a new one if it’s blunt
– Choose the right tool and setting according to the characteristics of the material
– Adjust the settings to proper specification for particular cutting tool
2. Programming Errors
CNC machines are controlled by computers through the programming language, so there may be some issues due to errors in CNC programming. The lack of knowledge of G-codes, M-codes, CAD, and CAM software, incorrect programming such as wrong set-up and data, will lead to product errors and wrong motion sequencing. These problems can be difficult to diagnose for new operators.
– Train new employees comprehensively and adequately
– Experienced programmers oversee operations
– Provide detailed user manuals and instructions to new operators
– In rare cases, simply turn off the machine and reboot the system
– Properly set up and align mechanically
3. Poor Maintenance
If the CNC machines are not been cleaned and lubricated, dirt and debris will be built up on the equipment and affect the location and clamping of parts, and output of the machine, then causes reduced accuracy and precision. In addition, poor output and blockage prevent air circulation, resulting in spindle overheating during the process, and the machine is easy to be damaged.
– Clean and maintain the machine in use regularly
– Check levels of coolants or airflow
4. Chatter or Vibration
The excessive vibration or chatter in the CNC machine will lower the quality of the piece, affect the accuracy of dimensions, reduce tool life and durability, and even affect the service life of your machine. Chatter may occur to workpiece or tool, you can listen if there is the noise generated.
– Ensure the cut width or depth keeps deflection below 1/1000th of an inch
– Adjust the RPM of the machining process
– Use balanced tool holders when using spindle speeds above 8,000rpm
5. Clamping Problems
The material blank or workpiece can’t be fixed firmly by the chuck or the fixtures shift or vibrate during the manufacturing process, this may cause the wrong location, the processing is not smooth, the piece drops, and even an accident or other problems.
– Check and adjust the hydraulic pump and the hydraulic pressure setup
– Set the jaws properly to grip the material securely
– Check if the lubricant is adequate
– Make sure the piece is correctly positioned
– Check out other setup and devices